D5-Evo pocket mechanicalinstallation guide

LIGHT-INDUSTRIAL

SLIDING GATEOPERATOR

TM

1

6

7

10

11

1. D5-Evo controller

2. Courtesy light fuse

(3A F/B)

3. Gate mounted origin

marker

4. Origin marker bracket

5. Origin sensor

6. Side covers

7. Foundation plate

8. Motor fuse (30A ATO)

9. 1 x 12V 7.2Ah battery

10. Switch Mode 2A charger

11. Manual release access

door

6. D5-Evo identification

2

3

4

5

8

9

3. Icons used in this guide

2. Important Safety Instructions

This guide is designed specifically for installers who are familiar with

the installation of standard sliding gate motors, but do not know the

specifics of the D5-Evo.

Always ensure that all the safety instructions described in the

installation manual are adhered to during and after the installation

process is completed.

The D5-Evo is a domestic and light-industrial operator designed to

open and close sliding gates weighing up to 500kg. A custom designed

gearbox moulded from robust engineering polymers, coupled to a

powerful 12V DC motor, provides fast and reliable automation for

entrances to homes and small housing estates.

Please do not proceed with the installation until you have

read and fully understand the Safety Instructions

included in your product packaging

The Safety Instructions are also available on

www.centsys.com, and may also be obtained by

contacting Centurion Systems on +27 860 236 887

(RSA only)

1. Introduction

4. General description

This icon denotes variations and other aspects that should be

considered during installation

This icon indicates tips and other information that could be

useful during the installation

This icon indicates warning, caution or attention!

Please take special note of critical aspects that MUST be

adhered to in order to prevent injury

Fit endstops capable of stopping the gate at rated speed

Make H>h to ensure gate will not jump over endstop as shown

above

Ø16mmhH

Endstop

Endstop

Endstops

Guide-rollers must ensure that

the gate is held vertically through

the entire length of the gate

travel. For improved safety fit

additional support posts to

prevent gate from falling over

if guide-rollers fail.

Ensure that the gate

cannot be lifted off the

motor pinion with the

anti-lift bracket fitted

7. Preparation of site

General considerations for the installation

For comprehensive information, please refer to the full installation

manual available for download on www.centsys.com

Install the gate operator only if:

It will not pose a hazard to the public

There is sufficient clearance to a roadway and/or public

thoroughfares

The installation will meet all municipal and/or local authority

requirements once completed

The gate mass, length and application is within the operator

specifications

The gate is in good working order, meaning:

That it moves freely

Does not move on its own if left in any position

It can be installed to have sufficient clearance between

moving parts when opening and closing to reduce the risk of

personal injury and entrapment

Pushbuttons or keyswitches, when required, can be positioned

so that the gate is in line of sight of the operator

Make sure the gate mass,

starting - and rated-pull-force

limitations are not exceeded.

Pull scale

Guide-rollers

Additionalsupport post

GAP<5mm

GAP<5mm GAP<5mm

GAP<5mm

Typical anti-liftarrangements

It is a 12V DC battery operated unit with the following limitations:

Operator push force - starting 30kgf

Operator push force - rated 17kgf

Gate mass – maximum 500kg

Gate length – maximum 100m

Maximum numbers of operations per day 150

Degree of protection IP54

5. Technical specifications

9. Cabling requirements

1

6

5

78

8

3

D5D5EvoEvoEvo

44

8. Lubrication

1. Lift the cover of the

operator.

2. Remove the battery so that

you can gain access to the

coloured filler plug.

3. Remove the coloured oil filler

plug by levering it out with a

screwdriver.

4. Empty the contents of the oil

bottle into the gearbox

(80ml).

5. Refit the coloured oil filler

cap.

Put 80ml oil in here

Oil specificationsCEN

product code:

OIL80ML0X0/H

Castrol SAF-XO 75W-

90 Synthetic Final

Drive Lubricant

Do not attempt to run the operator without first filling the

gearbox with lubricant

Legend

1. 220V - 240V AC mains cable via double pole mains isolator switch2 (3 core LNE 1.5mm SWA)

Optional wiring (all cable is multi-stranded):22. Intercom cable from motor to dwelling (n1 + 6 core 0.5mm )

23. Intercom cable from motor to entry panel (n2 0.5mm )

4. Safe Close and

Safe Open: Recommended infrared safety beams 2

(3 core 0.5mm )

25. Trg: Access control device (3 core 0.5mm )

6. Ped: Optional pedestrian keyswitch (a) OR keypad 2 (b) (3 core 0.5mm )

27. Trg: Optional external radio receiver (3 core 0.5mm )

8. Light: Optional pillar lights (3 core LNE SWA, size

according to power requirements)

n1 = number of cores required by intercom

n2 = number of cores required by intercom

Possibly increase cable thickness if pillar lights are installed

Type of cable must adhere to municipal bylaws but typically SWA

(steel wire armoured) cable is recommended. The armouring

provides excellent screening, which gives better protection against

lightning – earth one end of the screening)

Allows for all features such as pedestrian opening, status LED, etc.,

to be operated from the intercom handset inside the dwelling.

Number of cores and type of cable could vary depending on brand

of access control system being used

For optimum range, an external receiver can be mounted on the

wall

10. Manual operation

D5D5D5evoevoevo

1. Insert the camlock key and

rotate it 90° clockwise.

This will allow for the removal

of the cover, as well as for the

rotation of the release

thumbwheel.

Do not remove the

thumbwheel. Removal of

the thumbwheel may

result in water entering

the gearbox and the

warrantee will be void

Disengage gearbox/drive

2

Oil filling procedure

D5D5D5evoevoevo

D5D5D5evoevoevo1. Rotate thumbwheel anti-

clockwise until thumbwheel

feels loose in the hand. Make

sure that the manual override

access door can be closed.

2. Slide gate until gearbox/drive

engages. Never run the

motor before the unit is

engaged.

Re-engage gearbox/drive

Ensure that all the standard considerations for a quality

gate installation are adhered to as detailed in

CENTURION’s detailed installation manuals. These must

include:

11. D5-Evo operator installation

Correct access in and out of the premises

Endstops are mandatory and must be capable of stopping the

gate at rated speed

Guide-rollers and anti-lift brackets are correctly fitted

The gate mass, starting- and rated-pull-force limitations are not

exceeded

The D5-Evo is positioned correctly and does not protrude into the

driveway

2. Rotate thumbwheel clockwise until gearbox releases and gate can be moved manually.

3. If the gearbox must be left in manual mode for an extended period of time for whatever reason, it is recommended that the access door is locked. This secures the cover and prevents access to the inside of the unit, which contains high voltages. It also prevents theft of any components and provides full protection from the elements.

B: Above pinion - Steel rack

* Includes 3mm clearance required between rack and pinion

5

32 - 50

(R

eco

mm

en

ded

to

all

ow

fo

r ad

justm

en

t)

82

146*

Foundationplate

Flat bar welded tofoundation plate and rail

1. To ensure operator does not

protrude into driveway, install

base plate at least flush with

the driveway entrance.

2. Determine a suitable position

and vertical height for the

operator by considering

Figures A, B and C.

A: Above pinion - Raz rack

5

32 - 50

(R

eco

mm

en

ded

to

all

ow

fo

r ad

justm

en

t)

82

16

3*

Foundationplate

Flat bar welded tofoundation plate and rail

* Includes 3mm clearance required between rack and pinion

Locate operator position

1. Route cables as determined

in Section 9, Cabling

requirements.

Make sure that all cables

protrude at least 400mm

above the baseplate once

installed as shown in the

illustration

2. Securely concrete or bolt

the foundation plate in position.

Route cables and secure foundation plate

40

0m

m

M10mounting bolts

30

mm

5

32 - 50

(R

eco

mm

en

ded

to

all

ow

fo

r ad

justm

en

t)

82 1

37

*

Foundationplate

Flat bar welded tofoundation plate and rail

C: Above pinion - Nylon angle rack

* Includes 3mm clearance required between rack and pinion

With careful selection of the rack configuration, and operator vertical height, mounting of the rack could in some cases be greatly simplified

If a theft-resistant cage is required, be sure to leave enough clearance from pillars, etc.

If using nylon angle rack please ensure that the weight and pull force of the gate do not exceed the strength limit of the rack

The foundation plate can either be set into a concrete foundation, or bolted down onto an existing concrete plinth, refer to illustrations below.

Foundation plate installation

M10 gearbox

mounting bolts

Use two M12

plated nuts as spacers

M10 x 95 expansion

stud

M10 nutM10 washer

If bolting onto an existing

concrete plinth, place the

foundation plate down in the

correct position and use the plate

as a template for marking the

rawl bolt holes.

Assemble foundation plate without

anchor brackets before bolting

down onto plinth.

Ensure that the M10 gearbox mounting bolts are properly tightened

Option 2:

Bolting foundation plate onto an existing concrete plinth

New concrete foundation

Assemble foundation plate with

anchor brackets as shown in the

illustration.

• Ensure that the M10

gearbox mounting bolts

are properly tightened

• Cable conduits must be

installed before pouring

the concrete

400mm

M10 gearbox

mounting bolts

400mm

300mm

Option 1:

Steel rack

1. Fix rack using the steel angle

brackets provided.

2. Brackets must be spaced no

more than 300mm apart.

3. When joining different

lengths of steel rack, a

simple way of ensuring

correct pitch spacing, is to

clamp a small off-cut

between the two pieces.

±300mm

±300mm

Pillar lights

Signal cable

Mainssupply

M10washer

M10nut

Mount the gearbox

3. Remove the knock-outs for

the cables from the gearbox.

4. Feed the cables through

these holes while fitting the

gearbox to the baseplate.

5. Note how the cables route up

onto the control card.

6. Check that the operator is

level.

7. Secure the gearbox in place

fitting the following in

sequence: first a nut and

then a washer onto each

gearbox mounting; then the

gearbox; and then a washer

followed by a spring washer

and finally a nut onto each

gearbox mounting.

8. Do not mount gearbox flat

down onto mounting plate.

Adjust the height of the

mounting nuts to raise the

gearbox at least 5mm above

the plate. This is to allow for

later adjustments.

9. Seal the conduit and knock-

out holes in the operator

with silicone sealer to

prevent ants from entering

the operator through these

cable entry points.

The rack must be securely

mounted to the side of the

gate. It must be parallel

with the gate rail, and

there must be a 2 - 3mm

gap between the teeth of

the pinion and the rack,

along the entire travel of

the gate

Mount the rack

5mm

3mmtooth gap

Mounting the originmarker

1. Close the gate completely.

2. Mount the origin marker to

the rack a minimum of 500mm

from the origin sensor.

3. For steel rack mount the

origin marker onto the rack

using the bracket provided.

4. Weld the bracket to the

rack.

5. Bolt the origin marker onto

the bracket using the fasteners

provided.

Steel rack

6. With RAZ rack the origin

marker mounts directly on

top of the rack without a

bracket.

7. Drill mounting holes

directly into the rack and

bolt into position.

8. File away the front lip of

the rack if you need to move the

origin marker closer to

the operator as the gate

slides past.

RAZ rack

9. With nylon angle rack it is

necessary to use the bracket

provided.

10. It is preferable to use self-

tapping fasteners to secure

the bracket into the side of

the nylon rack as shown.

11. Make a small tack weld to

secure the back of the bracket

onto the angle iron section of

the rack.

12. Bolt the origin marker onto

the bracket using the fasteners

provided.

Nylon angle rack

Bolt usingfastenersprovided

Origin markerbracket

Screw into side of the nylon rack

Nylon angle rack

Bolt usingfastenersprovided

Origin markerbracket

Weld mountingbracket provided to

steel rack

Steel rack

Mounting the origin marker (continued)

13. Manually slide the gate

OPEN until the origin marker is

in line with the origin

sensor.

RAZ rack

1. Use at least three TEK screws per half metre section of rack.

Fit additional fixing screw through the horizontal slots to secure

the rack to the gate directly above the pinion when the gate is

in the closed, pedestrian and open positions

Gateclosed

Pedestrianopening

Gateopen

D5D5D5

Gate closed Pedestrian Gate open

A10 A10

Isometric view

Greater than 500mm

Bolt usingfastenersprovided

RAZ rack

Greater than 500mm

Gate in closed

position

Originmarker

Plan view

Apply warning decal/signageApply the supplied Warning! decals/signage to the gate

It is possible to make the distance between the marker and the

sensor much greater than 500mm. However, if using the

pedestrian opening facility, although the position of the marker

will not affect the width of the pedestrian opening, it is

preferable to have the marker mounted inside of the pedestrian

opening point

14. Ensure distance between

face of marker and front

face of sensor is between

13mm and 20mm.

Take care with the

orientation of the arrow on

the origin marker. This

arrow must face the

operator

15. Adjust distance by sliding

the origin marker along the

slotted mounting holes until the

specified distance is

For best results keep gap

between marker and

sensor as small as

possible

Originmarker

Gate

Rack

Plan view

CENTURION operators are designed to be maintenance-free. However,

there are some basic checks that should be carried out regularly,

(every six months). These checks will increase the long term reliability

of the system and prevent erratic operation of your gate.

Isolate mains supply as well as disconnecting the

battery before cleaning or working on the equipment.

General

Keep the track clear of stones, dirt and obstructions

Ensure that all rollers run freely

Put the operator into Manual Mode and check that the gate runs

freely on its rail and does not catch or foul against the walls or

pillars

Ensure that the gate wheels and guide-rollers are rotating freely

and are not worn. In high-volume applications it will be necessary

to replace these components regularly

Ensure that the rack is properly secured to the gate and that it

does not press down onto the operator pinion at any point along

its travel

Keep shrubs and vegetation clear of the motor and rack

Check that the key still operates the camlock - spray with

lubrication if necessary

Keep the inside of the motor housing clear of insects and dust

Battery

CENTURION operators, which are fitted with maintenance-free lead

acid batteries, should provide at least three years of normal service

life.

For sites utilising an external large capacity (+/-35Ah) low

maintenance battery, ensure that the level of liquid (electrolyte level)

is correct.

In all instances check for corrosion of the battery terminals. Clean and

apply copper-based grease as necessary.

12. Basic maintenance

Charger

The D5-Evo operator has a charger separate to the main controller. In

the case of product malfunction, the charger fuse should be checked,

but only by a qualified electrician. Always isolate the mains supply to

the operator before attempting to remove and check the fuse.

Check the “Mains Present” icon on the main diagnostic screen or

switch to the battery charger diagnostic screen and check the charger

voltage – right hand value. This should indicate, 13.8V for the

D5-Evo. Each charger has a red light (LED) to indicate mains supply.

Gearbox Oil Level

Check the oil level as described in section 8 of this document or refer

to the online manuals on our website, (www.centsys.com).

Alternatively, please contact your CENTURION installer for assistance

Origin sensor

Originsensor

13-20mm

Once the installation has been successfully completed and tested, it is

important for the installer to explain the operation and safety

requirements of the system.

NEVER ASSUME THE USER KNOWS HOW TO SAFELY OPERATE

AN AUTOMATED GATE!

Even if the user has used one before, it does not mean he knows how

to SAFELY operate it. Make sure that the user fully understands the

following safety requirements before finally handing over the site.

The following needs to be understood by the user:

How to operate the manual release mechanism.

(Show them how by demonstration)

How the obstruction detection and all other safety features work.

(Show them how by demonstration)

All the features and benefits of the operator, i.e. Safety beams,

ChronoGuard, etc.

All the safety considerations associated with operating an

automated gate. The user should be able to pass this

knowledge on to all other users of the automated system

and must be made aware of this responsibility.

Do not activate the gate operator unless

you can see it and can determine that its

area of travel is clear of people, pets, or

other obstructions

NO ONE MAY CROSS THE PATH OF A

MOVING GATE. Always keep people and objects away

from the gate and its area of travel

NEVER LET CHILDREN OPERATE OR PLAY WITH THE

GATE CONTROLS, and do not allow children or pets near

the gate area

Be careful with moving parts and avoid close proximity

to areas where fingers or hands could be pinched

Secure all easily accessed gate operator controls in

order to prevent unauthorized use of the gate

Keep the automated gate system properly maintained,

and ensure that all working areas are free of debris and

other objects that could affect the gate operation and

safety

On a monthly basis, check the obstruction detection

system and safety devices for correct operation

All repair and service work to this product must be done

by a suitably qualified person

This product was designed and built strictly for the use

indicated in this documentation. Any other use, not

expressly indicated here, could compromise the good

condition/operation of the product and/or be a source

of danger!

CENTURION SYSTEMS (Pty) Ltd. does not accept any liability caused by improper use, of the product, or for use other than that for which the automated system was designed.

Ensure that the customer is in possession of the User Guide and that you have completed the installation details in the back of the User Guide.

13. Installation handover

www.centsys.com

0.07.A.0046_22072013

Sharecall 0860-CENTURION (0860 236 887)Head Office: +27 11 699 2400

Sharecall Technical Support 0861 003 123 or +27 11 699 2481from 07h00 to 18h00 (GMT+2)

(Sharecall numbers applicable when dialed from within South Africa only)